By James Kennedy, a technology analyst at market intelligence firm IDTechEx.

The advanced recycling market for plastics predominantly focuses on technologies like pyrolysis and depolymerization (thermal, chemical, and enzymatic). To a lesser extent, methods such as gasification and hydrothermal liquefaction are also being explored. However, these technologies face increasing scrutiny and restrictions in some regions due to their environmental impact. However, while mechanical recycling is the preferred recycling method due to its cost-effectiveness and efficiency, it still falls short in applications requiring high purity and mechanical properties. To address these challenges posed by both chemical recycling technologies and mechanical recycling, dissolution technologies (sometimes referred to as solvent extraction) offer a promising solution.

Dissolution explained
Dissolution involves separating polymer waste using a solvent. The solvent selectively dissolves the polymer, separating it from contaminants and other non-target materials. Once dissolved, the solution is purified, and the solvent is removed, leaving behind a nearly pure plastic that can be processed back into granules for reuse in manufacturing.

This method can deal with contaminated or mixed plastic waste that is challenging to recycle through mechanical means while not breaking the polymers into their constituent molecules or feedstock. The need to carefully separate different polymer types is reduced, as plastic types can be selectively dissolved and separated out when using the correct solvent mixture. The processes are designed with solvents and separation methods for specific plastic types such as polypropylene, polystyrene, and acrylonitrile butadiene styrene.

PureCycle Technologies is a notable player in the field of plastic dissolution. The company utilizes a proprietary technology developed by Procter & Gamble to recycle polypropylene. Its process involves using a solvent (primarily n-butane) to purify waste polypropylene into a form that is comparable in quality to virgin plastic. PureCycle states that its recycled PP can be used in applications where mechanical recycling methods, such as food-grade packaging, would not suffice. PureCycle is currently the leading commercial-scale provider in this space.

The key advantage of dissolution is the higher theoretical overall yield that it can provide compared to chemical recycling technologies, as the product re-enters the plastic supply chain as a ready-for-use resin rather than simply a polymer building block or a hydrocarbon.

As a relatively nascent industry, there is continuing R&D on its processes. One standout is Solvent-Targeted Recovery and Precipitation (STRAP), which is a new technology framework that researchers at the University of Wisconsin-Madison have developed. The technology can separate the components of multilayer plastic films and remove contaminants. Multilayer films are a key challenge in plastic waste management, and as a result, the commercialization of this technology has strong potential. Additionally, the developers of STRAP claim the process has many advantages over competitors, including operation at atmospheric pressure and lower temperatures. At present, a STRAP pilot plant is being built at Michigan Tech University to prove the technology. The promise of a highly adaptable dissolution system for this type of hard-to-recycle plastic waste would be the most sought-after solution. The technical challenges of scaling STRAP will likely mean several years before this is at a commercial scale.

The general process for the dissolution of plastic waste (source: IDTechX). Click image to enlarge.

Dissolution drawbacks
While dissolution technology holds promise, it is not without its challenges and criticisms. For example, there are questions about long-term circularity as the polymer is likely to degrade over successive cycling. Another concern with the dissolution process is the environmental impact of the solvents used. These chemicals must be managed carefully to avoid releasing harmful substances into the environment. The energy required to heat the solvents and subsequently remove them from the dissolved plastic also adds to the carbon footprint of the process.

The economic viability of dissolution technology also remains uncertain. The cost of the solvents, energy consumption, and the need for sophisticated infrastructure will likely make recycled polymers from dissolution plants more expensive than with mechanical recycling methods. The size of this green premium versus other recycling technologies will determine whether dissolution plants can be economically viable.
Furthermore, the scale required to make a significant impact on plastic waste through dissolution is immense. Building the necessary infrastructure to process large volumes of plastic waste through dissolution is a massive undertaking that will require substantial capital investment and time.

The success of dissolution technologies like PureCycle’s depends on market demand for recycled plastics. While there is growing interest in sustainable materials, competition from cheaper, virgin plastics can limit the market potential for recycled products. Future efforts will focus on developing processes for a wider range of polymer types. Companies such as APK, Worn Again, and Polystyvert are working with polyethylene (PE), polyethylene terephthalate (PET), and polystyrene (PS), respectively. The Netherlands Organization for Applied Scientific Research (TNO) is developing a process called Mobius for recycling acrylonitrile butadiene styrene (ABS), though it is not yet commercialized.

Dissolution presents a promising technology for addressing the demand for low-carbon, versatile plastic waste solutions. However, several hurdles remain, including technological refinement, commercial scaling, and economic challenges. Stakeholders must carefully evaluate the benefits and drawbacks of dissolution within the broader context of global waste management strategies. Navigating economic challenges will be key, as price will be the determinant factor in success as companies adopting recycled polymers evaluate how much of a green premium they can afford. Continued research, investment, and regulatory support will be essential to refine the process and assess its long-term viability as part of a comprehensive effort to mitigate the impact of plastic waste on the environment.

Developing new kinds of recyclable fibre-based products is the aim of an initiative in Scandinavia, which aims to reduce energy and resource consumption in the forestry and textile industry.

The goal of the Energy First initiative, says VTT Technical Research Centre of Finland, is to act as a starting point for an entirely new technology, creating “the conditions for the manufacture of low-carbon, energy-efficient, and recyclable fibre-based products”.

With trends such as the continued growth of global e-commerce, the demand for fibre-based packaging is projected to grow 5–10% annually.¹ It needs to be easy to recycle and have a low carbon footprint. Within non-wovens, used in napkins and wipes for example, VTT said it expects a strong shift away from traditional products (that contain plastic) towards cellulose-based products.

It has a budget of around 20 million euros over the next four years, and consists of several projects, with collaborative research aiming to develop and test commercially viable, sustainable alternatives for cardboard packaging, hygiene products, and non-woven fabrics.

According to VTT, preliminary estimates suggest the new manufacturing process will provide a reduction of up to 90% in water consumption and a significant decrease in carbon emissions. Overall, the goal is to reduce energy consumption by up to 50%.

Products manufactured with the new process are designed to be compatible with existing recycling methods. Furthermore, fibre-based packaging is produced in a way that makes it a sustainable alternative to reusable packaging, said the group. The planned EU packaging and packaging directive requires that both the raw material and the manufacturing process are sustainable, and recyclable bio-based packaging solutions will have to undergo a sustainability assessment.

The project also seeks to redefine the forest industry’s environmental impact and enhance the competitiveness of fibre-based products. For example, by making the products lighter, more products could be produced for consumer use from the same amount of wood, which improves resource efficiency.

“We feel that the Energy First project is one of the first steps in unlocking the full potential of airlaid technology² in sustainable single-use and durable product categories. Anpap³ has set the benchmark for the airlaid industry for the past 40 years, and we have a strong commitment to keep developing the technology to enable the transition to next-generation sustainable products. Compared to wetlaid, airlaid web forming is flexible and consumes dramatically less natural resources, such as water, which reduces the environmental impact of manufacturing and while satisfying the needs of consumers,” says Tuukka Vihtakari, CTO, Anpap.

The initiative is funded by EU, ERDF, VTT and the collaborating companies. The consortium is also engaging with EU projects, such as EU SteamDry, with a total budget of 9.84 million euros over 3.5 years.

Notes
[1] According to data from Statista Market Insights and eMarketer
[2] The term refers to a manufacturing process used to produce nonwoven materials, particularly those made from natural fibres like cellulose, wood pulp, or a mixture of various fibres. This technology involves forming a web of fibres using air as the medium to distribute them, rather than traditional textile processes like weaving or knitting.
[3] A Finnish manufacturer of airlaid machinery

The US Plastics Pact has released its Design for Circularity Playbooks, described as essential reports designed to guide the lifecycle of plastics in the US.

“The newly unveiled Design for Recyclability Playbook, Design for Reuse Playbook, and Design for Compostability Playbook provide detailed guidelines to ensure that plastic packaging is continuously reused, recycled, or composted, thereby reducing plastic waste and its environmental impact”, says the group.

The US Plastics Pact describes itself as a solutions-focused consortium of businesses, government agencies, NGOs, and research institutions at the forefront of efforts to foster a circular economy for plastics. By bringing together diverse stakeholders, the group aims to drive systemic change across the plastics value chain. These playbooks are presented as tools for industry insiders and essential guides for anyone committed to sustainability.

“These reports are crucial tools that hold all of us accountable for designing sustainable and environmentally friendly plastic packaging,” said Jonathan Quinn, CEO of US Plastics Pact.

“By providing clear, actionable guidelines, we empower companies and organizations to make informed decisions to drive substantial improvements in plastic design and management.”

Integrating sustainability into plastic design
Together, the three reports are said to offer a comprehensive strategy for integrating sustainability into the design and lifecycle of plastic packaging. The Design for Recyclability Playbook ensures that plastic packaging is compatible with existing recycling systems. It sets expectations for designing new packages and optimizing existing ones, aiming to maximize recycling value and minimize the use of problematic materials that interfere with recycling processes or contaminate recycled content. This approach enhances the efficiency and efficacy of recycling systems and increases national recycling rates, contributing to a more sustainable plastic lifecycle.

The Design for Reuse Playbook addresses the demand for sustainable packaging solutions by providing a toolkit for developing and implementing reusable packaging systems. Aligning with the global principles of the Ellen MacArthur Foundation, this playbook promotes systems that support repeated use, reducing reliance on single-use plastics. This initiative is critical for businesses looking to minimize waste and foster a culture of reuse.

The Design for Compostability Playbook explores how businesses can create compostable packaging that supports the development of organics diversion systems in the U.S. The guidelines ensure that compostable packaging breaks down efficiently in composting facilities, converting waste into valuable compost that can enhance soil health and support sustainable agriculture.

Driving responsibility and accountability
As the group explains: “Integral to the paradigm shift toward sustainable plastics packaging design, these playbooks establish best practice guidelines that promote designing for multiple uses, enhancing recyclability, and producing high-quality recycled content. This ensures a unified and practical approach to achieving sustainability goals in plastics management, fostering responsibility and accountability across all stakeholders.”

In June, the US Plastics Pact launched its strategic plan, Roadmap 2.0, which summarizes its achievements to date and sets out targets for the future. “Stakeholders are encouraged to adopt these guidelines to help create a circular economy where plastics are continuously reused, recycled, or composted. This proactive approach will significantly reduce environmental impacts for a healthier planet.”

For more information and to access the playbooks and the report, visit usplasticspact.org.

A giant pink cat hologram will be surprising commuters at London Waterloo from Tuesday 20th August. The hologram is seemingly an effigy of HypnoCat, Recycle Your Electricals’ pink, fluffy mascot, which will be playfully leaping out at commuters, tail a-twitching and eyes a-swirling.

The giant, 3-metre-tall pink HypnoCat will be seen pouncing on commuters and mesmerising them as electrical items spiral around him, seemingly highlighting the tech items that he wants everyone to recycle. The state-of-the-art technology, provided by HyperGram, uses the latest holographic technology, without the need for a screen or glasses. 3-D objects float mid-air, ensuring that HypnoCat and his message are impossible to ignore. He’ll make recycling electricals unmissable for commuters, holiday goers and shoppers.

The HypnoCat hologram is being launched in the run-up to International E-Waste Day (October 14th), to encourage people across the UK to participate in The Great Cable Challenge. This nationwide campaign aims to address the millions of unused cables lying idle across homes by urging households, local authorities, retailers, schools and community projects to collectively recycle 1 million cables. Cables contain at least 20% copper and this precious material is lost forever when cables and other electricals are thrown away. Copper is an essential part of everyday items we take for granted, including our smart tech, transport, medical equipment and our green energy future.

Scott Butler, Executive Director of Material Focus said, “HypnoCat is out and about and larger than ever before! Using incredible hologram technology in this unique visual way, we hope he will pawsuade many more people to take action and join us in our recycling efforts in the run up to International E-Waste Day.

“Almost all of us have those old, forgotten cables stashed away at home – I have a box under my bed of cables I’ve been holding onto ‘just in case’ but haven’t actually used in months or are broken. But by recycling them or donating those that still work, we can repurpose or reclaim that valuable copper currently going to waste. The Great Cable Challenge is a simple way for everyone to make a big, collective difference – by recycling at least one cable. Most people will be surprised at just how easy it is to do.”

As a nation of cat lovers, we all know that “cats rule” and this cat is no exception – he’ll be distracting commuters, and even a few dogs! With his tail twitching impatiently, and his voice booming, he’ll compete with essential train information. Commuters at Waterloo on 20th – 24th August will find HypnoCat in 3D underneath the big train time information board.

Bailey Young, Director at DMG said, “Disturbed Media Group, an innovative agency at the forefront of immersive experiences, is proud to announce the showcase of its latest project in the UK, HyperGram. Leveraging state-of-the-art 3D holographic technology developed by our esteemed tech partner, Hypervsn, HyperGram transforms traditional visual storytelling by creating animations that appear to float in mid-air.

It’s been a joy bringing to life Hypnocat which seemed incredibly fitting to what we were trying to achieve this year. We hope consumers around London have a really enjoyable experience and we look forward to the results of the campaign!”

How can you get involved in International E-Waste Day?
Anyone can participate in The Great Cable Challenge and take one small action to make a big difference. Simply bag up your cables – and any other old, unwanted electricals you find in your ‘drawer of doom’ – and visit Recycle Your Electricals’ postcode locator to find your local donation or recycling point.

Material Focus has created a campaign toolkit to enable local authorities, retailers, schools and community projects across the UK to take part in the challenge and help inspire people to recycle their old cables and other small electricals. If you would like more information then please email hello@materialfocus.org.uk.

Partners can either:

• Set up pop-up cable collections in offices, universities, schools and community halls, to make it as easy as possible for employees, students or residents to recycle their household electricals and cables. The toolkit includes a step-by-step guide for setting up your own pop-up collection point (for household electricals only, not business waste).
• Help promote the campaign using Material Focus’ communication materials, and raise awareness of electrical waste and encourage individuals, and local communities, to take action.

Researchers at the University of Illinois Urbana-Champaign have developed a Circularity Index that they say provides a comprehensive method to quantify circularity in bioeconomic systems. In a new paper, they outline the method and apply it to two case studies – a corn/soybean farming operation and the entire US food and agriculture system.

“The traditional economic system is linear – we produce, distribute, use, and dispose of products. To increase sustainability, we need to develop a circular economy. Rather than just using natural resources, we must recover, reuse, and recycle waste materials,” said lead author Yuanhui Zhang, a professor in the Department of Agricultural and Biological Engineering (ABE).

“Circular bioeconomy has become a hot topic in research, but most studies are merely descriptive and there’s no way to measure impacts. To move the technology forward, we need measurements to quantify effects, establish benchmarks, compare approaches, and identify weak spots,” he said.

In the paper, the researchers provide a step-by-step outline of the Circularity Index (CI), which measures circularity on a scale from 0 to 1. Zero means the system is completely linear, and 1 means it is completely circular. The index includes eight categories: take, make, distribute, use, dispose, recover, remake, and reuse. The CI is computed by entering available data into each of these categories.

Zhang and his colleagues demonstrate how to use the CI in two case studies. The first examines nitrogen cycling in a corn-soybean farm in the Midwestern United States. The researchers enter production and output data for a period of 8 years, and compare the effect of two different fertilizer treatments: urea versus manure. They calculate the CI to be 0.687 for urea and 0.86 for manure, indicating the use of manure fertilizer provides a more circular economy.

In the second case study, Zhang and his colleagues look at the U.S. food and agriculture system, focusing on energy use. Drawing on national data from the USDA, EPA, and DOE, they compare the current system with an approach based on the Environment-Enhancing Food Energy and Water System framework, which involves recovery, remake, and reuse of organic waste. They find the existing system has a CI of 0.179, while the EE-FEWS approach would lead to a CI of 0.84.

“Our current production system relies primarily on fossil fuel, with some use of solar and wind energy. But there is very little recovery of biowaste. If we recover food waste and manure and turn it into energy and fertilizer, we can recycle it back to the agricultural systems it originates from. Employing the EE-FEWS framework would greatly improve circularity of the U.S. bioeconomy,” Zhang explained.

The CI is a scalable method that can be used on different resource types and systems, depending on the focus of interest. Resources can be minerals, such as carbon or nitrogen, or non-mineral, such as water or energy. Systems can range from a process or a farm to an industry sector, a national economy, or even the global economy.

“We know it’s important to reduce fossil fuel use, increase renewable resources, and minimize our water consumption. But to do so effectively, we need to know how much, and what the weak links and tradeoffs are. The CI provides a single number that allows you to establish a baseline, compare systems, and determine best strategies for action,” Zhang said.

The CI can serve as an indicator to support policy initiatives such as the United Nations’ Sustainable Development Goals. It also has potential commercial value; for example, food companies can demonstrate their production circularity to consumers.

The paper, “A scalable index for quantifying circularity of bioeconomy systems,” is published in Resources, Conservation and Recycling [DOI: 10.1016/j.resconrec.2024.107821].

Chris Williams of software firm ISB Global makes the case for digitalisation as the means for a less wasteful, more resource-efficient global economic model.

A circular economy involves building a ‘zero waste’ approach into everything we do. From reducing the volume of raw materials needed to make products, to ensuring there is a sustainable approach for disposing of products when they reach their end of life – these steps all reduce waste, which in turn reduces greenhouse gas emissions and conserves the environment.

The road to building a sustainable circular economy is now a digital issue. For it to become a reality, business, organisations, and governments must use digital to put in place their own low-waste circular approaches.

Digitalisation can not only enhance operational performance by providing clear visibility across all business functions but also allow better access to forecasting data. A low code approach can play a key role in this process.

Low-code software as a catalyst for transformation
With the emergence of low code software over the past 20 years, organisations have been able to achieve their digital transformation, faster and with greater accuracy.

The benefits are clear. Low code-based software applications reduce costs making collaboration easier and speeding up development and rollout, as well as supporting new features and providing continual updates, which can be designed, programmed, tested and released in a fraction of the time of traditional hand coding.

Its ability to bring platforms and applications to market more quickly also allows organisations to respond to new developments, add new features and functionality, and deliver a better user interface and user experience

ISB Global has used our partner OutSystem’s low code platform to harness these advantages and meet the particular needs of waste management operators and other companies who use our Waste and Recycling One platform to build an adept sustainable operating model.

Platforms like this gives organisations the all-important insight they need to become more agile and respond to new developments and challenges as they arise.

Digitalisation can make the circular economy a reality
There are three principal ways in which digitalisation can reduce environmental impact and facilitate a more circular low-waste economy:

• Improving resource efficiency

The extraction of raw materials used to make products – whether by drilling, mining, quarrying or farming – damages the environment, generates harmful emissions, and depletes the planet’s natural resources.

To move to a circular economy, manufacturers and producers must identify and source alternative materials that are less environmentally harmful: or reuse existing materials. Digitalisation enables businesses to track materials through their lifecycle: and also, accurately measure the benefits of using alternative materials or reusing existing ones.

• Increasing resilience

Companies are already having to deal with more incidents of supply disruption and shortages caused by extreme weather, conflict or other unexpected events. These occurrences are likely to increase in future.

The onus now is on businesses to secure resources and maintain supply chains or establish alternative ones. AI-assisted forecasting that accurately predicts supply and demand needs, and which also identifies potential weaknesses in operations before they become a problem, gives organisations the means to boost their resilience by pre-empting possible supply chain disruptions and shortages.

• Smarter designs for a circular approach

Digital tools will help businesses to design products and services that support a circular economy – everything from assessing the suitability of new materials: re-designing products where necessary, managing assembly and disassembly: and separating materials at the end of a product’s life for reuse elsewhere.

Digitalisation has the transformational potential to adapt how businesses work and establishing a less resource-intensive, more circular low-waste economy. This is essential for conserving our environment at a local, national and international level.

The implementation of different digital technologies has the potential to make a low-waste circular economy a reality by enhancing the workflows and operational efficiency. Coupled with old-fashioned human inventiveness and endeavour, the latest digital technologies can offer significant opportunities for progress.

Rather than seeing digitalisation as a necessary operational cost, companies should instead regard it as an investment that will strengthen their business, boost performance, and inspire new ideas and opportunities – all while contributing to a healthier, more sustainable way of life.

Chris Williams is CEO of ISB Global, a UK-based provider of planning software for the global waste management and recycling industry.

Bristol-based beer importer Budweiser Budvar UK has contributed more than £400,000 to a national environmental charity after failing to register as a producer of packaging.

According to the Environment Agency, the company should have registered in 2004 under regulations on packaging waste and taken steps to ensure the waste was recovered and recycled. An investigation two years ago found that the company had failed to do so, and the agency said the company claimed it had been unaware of the regulations until it stepped in.

Following the investigation, the company has now contributed £414,003.54 to Keep Britain Tidy for use in their Great British Spring Clean campaign. The sum was paid as part of a reactive Enforcement Undertaking – a legal agreement between the Environment Agency and an offender as an alternative action to prosecution or other monetary penalty.

The payment was agreed as the amount saved by the company in not recycling or recovering packaging waste, plus a penalty of 30 per cent. In addition, it has covered the Environment Agency’s costs.

Jake Richardson of the Environment Agency said: “It’s important that businesses take responsibility for the packaging that they place on the UK market. The Producer Responsibility Obligations (Packaging Waste) Regulations ensure that businesses such as Budweiser Budvar UK Ltd contribute towards the cost of recycling the packaging that they add to the UK waste-stream.

“In this case, we investigated and found they had failed to comply with the regulations and had consequently not paid its rightful share towards the recycling of its packaging. When the company realised this, it wanted to do the right thing and so it submitted an Enforcement Undertaking offer, which ensured that all avoided recycling costs were donated to a project that will enhance, restore and protect England’s natural environment.

“Budweiser Budvar UK Ltd is now fully compliant with the Packaging Regulations and has put processes in place to ensure continued compliance in the future.

“Enforcement Undertakings, when appropriate, allow a better resolution for the environment than a prosecution and help offenders who are prepared to take responsibility for their actions to put things right voluntarily, in a way that directly benefits the environment and local communities.”

Product manufacturers’ use of packaging materials has decreased since 2019, says a new report from environmental compliance scheme Valpak. And in 2021, more plastic waste was recycled domestically than exported, for the first time. But the picture that emerges from profiling progress with specific materials appears somewhat mixed.

A detailed snapshot of these and related trends are provided by the PackFlow 2023 reports, commissioned by WRAP. James Skidmore, Director of Consulting at Valpak, commented: “As we approach the full implementation of Extended Producer Responsibility for Packaging (pEPR), accurate data and baselines are more important than ever.”

He continued: “The reports, which are used by UK governments to inform packaging policy, also offer valuable insights into packaging market trends. For example, we can see that since 2011, UK domestic recycling of plastic packaging has increased steadily. In 2021, it exceeded the amount of plastic waste exported for the first time. The reports also show us that, since 2019, the amount of paper packaging placed on the market has increased relative to plastic packaging.”

Holding more than 50 million SKUs, Valpak’s packaging and product database is the largest packaging data resource in the UK. The suite of six material-specific reports make use of this data to assess the state of the market in 2022. In addition to calculating the amount of packaging placed on the market and recycled, it details compliance projections to 2028 which, in preparation for pEPR, are also used by UK governments to inform decisions on business targets.

Adam Herriott, Senior Specialist at WRAP, said: “WRAP is proud to have worked with Valpak on the PackFlow 2023 reports. These reports are crucial for government policy-making, providing the accurate data needed to shape future packaging regulations. Moreover, they inform much of WRAP’s work, including initiatives like the UK Plastics Pact, helping us to drive significant progress in reducing plastic waste and increasing recycling rates. The insights from these reports are essential for understanding market trends and making data-driven decisions that support a sustainable future.”

Material-specific insights include:

Paper and card
Compared to previous Valpak PackFlow reports in 2019 and 2017, paper and card POM has reduced. UK domestic recycling declined between 2004 and 2010, with modest increases in the targets being met by export. The overall upward trend in export appears to have stabilised since 2017 (despite increases in the targets), with export tonnages fluctuating since this time in a range between 500–700k tonnes per quarter, and total paper and card recycling in a range of 850–1,000k tonnes per quarter. Paper and card packaging recycling targets have flat-lined.

Glass
The main driver for total glass packaging recycling is UK domestic recycling. Glass POM is down from 2019 and, since then, the level of glass packaging recycling has risen steadily to meet modest year-to-year increases in targets. During the past five years, total glass packaging recycling has fluctuated in a range around 350–500k tonnes per quarter. At around 17 per cent of total recycling, on average, the amounts of glass packaging waste exported are small in comparison to UK domestic recycling.

Plastic
Plastic POM has fallen since Valpak’s reports in 2019 and 2017. A strong upward trend in the total amount of plastic packaging waste recycled over the period 2004–2022 was driven by increases in the recycling targets. With UK domestic plastic packaging recycling static at around 50k tonnes per quarter until 2011, export of plastic packaging wastes has played a key role in meeting the targets over much of this period. However, since then, UK recycling of plastic packaging waste has increased steadily and, in 2012, it exceeded the amount of plastic waste exported for the first time.

Aluminium
Compared to 2019 and 2017, aluminium packaging placed on the market has increased. While there has been a slight upward trend in UK domestic recycling over the whole sample period, UK domestic recycling does not appear to be trended since around 2012. During the period 2004–2015 recycling target increases were largely met by increases in UK domestic recycling of aluminium packaging. Since 2015, the situation has reversed. UK domestic recycling has been broadly static, while the export of waste aluminium packaging has grown rapidly. In 2018, it exceeded UK recycling in 2018, while in 2022, 64 per cent of aluminium packaging waste was exported, mostly to Europe (Germany and Netherlands).

Steel
Steel POM has reduced compared to 2019 and 2017. While there was substantial volatility in the amounts of steel packaging waste recycled either in the UK or exported over the period 2004–2022, there has been no strong indication of any trends.

Wood
The volume of wood packaging placed on the UK market was stable between 2019 and 2022, but higher compared to 2017. Between 2004 and 2008, an upward trend was seen in total recycling; this peaked at an annual tonnage of 940k tonnes and was followed by a decline that continued to a low point in 2015. Since 2015, accredited wood packaging recycling has continued to increase despite a drop in 2020. Business targets saw a slow increase between 2004 and 2009, before stagnating until 2017. In 2018, targets saw a dramatic increase to 48 per cent in 2020, before dropping to 35 per cent in 2021 and stagnating.

To download the reports in full, visit: https://www.valpak.co.uk/?s=packflow%202023 

A new method to extract valuable bio-based chemicals from whisky distillery waste streams could transform manufacturing and be worth up to £90 million in global chemical manufacturing markets.

Scientists from RIPCELL, a chemical manufacturing business, are working with researchers from the University of Aberdeen to demonstrate the feasibility of recovering high-value compounds, such as lactic acid, from pot ale and spent lees – co-products of the first and second stages of the whisky distillation process.

These extracted chemicals have potential applications in sectors including pharmaceuticals, food and drink, and cosmetics, where manufacturing typically depends on unsustainable, petrochemical-derived ingredients.

The project was supported with funding from the Industrial Biotechnology Innovation Centre (IBioIC), with samples of waste streams provided by whisky group Chivas Brothers from 12 of its distilleries across Scotland.

The research team developed a process using a separation technique known as liquid chromatography to isolate and extract higher-value acids, initially from pot ale. It has now been adapted to retrieve additional solvents from spent lees.

While residue from pot ale is typically used in low value applications such as animal feeds, spent lees are currently discarded. Up to 10 litres of spent lees are generated for every litre of whisky made, and due to variations in distillery processes, water sources, and raw materials, co-products from different distilleries contain different chemical compounds.

A life cycle analysis of the process was also completed to quantify its environmental impact. The results showed that the bio-based chemicals produced through this method have a significantly lower carbon footprint compared to those produced through traditional petrochemical routes. Estimates suggest that on a global scale, the new manufacturing method for target chemicals could reduce industry emissions by 392 million kg of CO₂ equivalent per year.

Following the success of the feasibility study, the next phase for the team will involve scaling up the separation process to prove its viability at an industrial scale.

Dr Eve Wildman, founder of RIPCELL, said: “Around 2.6 billion litres of wastewater is produced from the Scottish whisky industry every year, so the potential of this process is huge. For decades, the majority of these co-products have been used as animal feed, but we have found a new, more valuable option to deal with spent lees that could change the ways in which distilleries manage and process their residues.

“At the same time, this could be transformational for the chemicals industry. By taking a sustainable approach to manufacturing key compounds, rather than using fossil fuels, RIPCELL can help to reduce greenhouse gas emissions from the production process. For every kilo of bio-chemicals produced, we can remove 1.59kg of harmful greenhouse gas emissions.”

Dr Liz Fletcher, director of business engagement at IBioIC, said: “This project is a brilliant example of how we can add economic value by taking a circular approach to co-products and applying biotechnology. For both whisky producers and the chemicals industry, this process marks a significant step forward in reducing the environmental impact of manufacturing. We look forward to supporting RIPCELL throughout its next steps to bring the process closer to commercial application.”

Dr Alan Mccue, senior lecturer at the University of Aberdeen, added: “The idea of utilising wastewater from a traditional industry like whisky production for the recovery of bio-based chemicals is highly innovative. It’s great to see Scottish heritage being linked to sustainable chemical production. The outcomes of this IBioIC funded project are really exciting, and I look forward to supporting RIPCELL in the next stages of its development.”

The Carpet Recycling UK annual conference recognised efforts to develop a circular economy in the flooring sector.

Speaking at the two-day event in July, Adnan Zeb-Khan of CRUK addressed the fact that energy-from-waste (a destination for over 200k tonnes of carpet and textile flooring in 2022, albeit diverted from landfill) is no longer a sustainable long-term route and circular solutions need to be developed. Delegates heard about research projects that could be applied to construction products and the cement industry.

Headlam presented findings on its pilot take-back scheme which is providing insight into behaviours around recycling flooring materials. Innovate Recycling unveiled results on recycling polypropylene from carpet into new polypropylene beads that can be spun into new yarn for carpet manufacture. Matoha presented its evolving infrared material identification gun which is using AI to identify thousands of different carpet chemistries, and IOBAC presented solutions for magnetic-carpet-floor-tiles fixing, said to be saving thousands of pounds on damage to subfloors during building interior renovations.

The conference also discussed the urgent need for stakeholders to come together to develop an Extended Producer Responsibility (EPR) scheme for the sector. Several speakers presented on schemes in Europe and the USA. Jane Gardner of ERFMI (European Resilient Floorcovering Manufacturers’ Institute) said: “On the circular economy, now is the time to act – politically, legislatively and technologically. Sustainability is becoming mandatory in the European Union. Our strategy recognises the need for waste management companies, recyclers and raw material suppliers to collaborate to ensure a workable solution for all stakeholders.”

An evening event saw the Carpet Recycling UK annual awards presented by Jonathan Middelkoop from Betap. CRUK thanked all those who entered this year. The winners were:

• Circular Economy Initiative of the Year – Robbert Wapstra, Edel Carpets; Highly Commended: Betap
• Reuse and Recycling Project of the Year – Richard Shea, Salvation Army Trading Company Ltd; Highly Commended: John Cotton Group & Designer Contracts
• Most Sustainable Product of the Year – Kate Burnett, Milliken; Highly Commended: Condor Group

The conference presented an opportunity for Cathie Clarke, CRUK’s new Managing Director to meet and network with some of their 134-strong membership. She said: “Having just joined CRUK Ltd at the beginning of the month, the annual conference was a perfect opportunity for me to meet a large number of members at once.”

“The conference was packed with interesting and inspiring presentations on innovation within the carpet recycling industry, circular economy and sustainability with high energy debates on important issues. I look forward to working closely with all our members and the board to raise awareness of the important work that is already being done and to develop an ambitious strategy of influence and change within our industry for the benefit of our environment.”

For more information, email: info@carpetrecyclinguk.com or visit www.carpetrecyclinguk.com.